An automated magnetic particle inspection robot for fillet welds

Abstract

This application provides an automated magnetic particle inspection robot for fillet welds, relating to the field of non-destructive testing (NDT) magnetic particle inspection technology. It includes a vertically mounted chassis with drive wheels. A side rail is connected to the front of the chassis, and a sliding frame moves along the side rail. A fixing component is connected to the sliding frame, and clamping wheels and a detection module are fixed to the fixing component. Both the drive wheels and clamping wheels rotate around their own axes and are vertically aligned. The drive wheels and clamping wheels are used to clamp wing plates. The detection module has a nozzle and a magnetic yoke. The nozzle sprays a magnetic suspension, and the magnetic yoke provides the magnetic field required for inspection. This solution can clamp H-beams, T-beams, and L-beams to achieve automatic guidance and movement, highly integrating magnetization, spraying, and image acquisition modules into one unit, improving inspection efficiency and safety.

Description

Technical Field

[0001] This application relates to the field of non-destructive testing magnetic particle inspection technology, and in particular to an automated magnetic particle inspection robot for fillet welds. Background Technology

[0002] Magnetic particle testing utilizes the magnetization of ferromagnetic materials to generate a leakage magnetic field at the defect location, attracting magnetic powder applied to the workpiece surface. Under appropriate lighting, this forms a visible magnetic trace, revealing the location, shape, and size of the defect.

[0003] Currently, for the inspection of fillet welds in large batches and various sizes of AP series welds (T-shaped, H-shaped, L-shaped steel) for nuclear power reactors, as well as large structural components in the special equipment and shipbuilding industries, manual handheld magnetic yoke inspection is mainly used. This involves inspectors holding a portable electromagnetic yoke (typically weighing 3-5 kg) across both sides of the fillet weld. First, magnetic suspension fluid (or dry magnetic powder) is sprayed onto the weld area, then magnetization is applied, and the magnetic traces are visually observed. After inspecting one section, the power is turned off, and the process is repeated for the next section. Furthermore, conventional magnetic yoke inspection uses a two-pole magnetic yoke flaw detector, requiring two separate magnetic yoke inspections at 90° angles, which is cumbersome and lacks high overlap accuracy.

[0004] The inspection of fillet welds for large quantities of structural steel often stretches for tens of kilometers. Manual inspection requires workers to bend over or lie prone, and they must carry heavy magnetic yokes for extended periods, resulting in enormous physical exertion. This leads to extremely low inspection efficiency (i.e., low productivity), and as worker fatigue increases, human error is highly likely to cause missed inspections or misjudgments.

[0005] In summary, there is an urgent need for a mobile robot device that can stably adsorb and adapt to different magnetization methods and fillet weld geometries, integrating automatic magnetization and magnetic suspension spraying, in order to solve the above problems. Summary of the Invention

[0006] To address the shortcomings of the existing technology, this application provides an automated magnetic particle inspection robot for fillet welds. This robot can clamp the wing plates of T-shaped, H-shaped, and L-shaped steel to achieve automatic guidance and movement. It highly integrates magnetization, spraying, and image acquisition modules into one unit, improving inspection efficiency and safety.

[0007] To achieve the above objectives, the present invention employs the following techniques: An automated magnetic particle inspection robot for fillet welds includes a vertically mounted chassis with a drive wheel on it. A side slide rail is connected to the front of the chassis, and a sliding frame is movable on the side slide rail. A fixing component is connected to the sliding frame, and a clamping wheel and an inspection module are fixed on the fixing component. The drive wheel and the clamping wheel both rotate around their own axes and are vertically arranged. The drive wheel and the clamping wheel are used to clamp the wing plate. The detection module has a nozzle and a magnetic yoke. The nozzle is used to spray the magnetic suspension liquid, and the magnetic yoke is used to provide the magnetic field required for detection.

[0008] The beneficial effects of this invention are as follows: (1) It replaces the traditional manual handheld magnetic yoke operation, while ensuring that the magnetic particle inspection process meets the standard requirements. The automated magnetic particle inspection robot can use 4 magnetic poles and complete 2 magnetization inspection methods by setting parameters through the control system: controlling the simultaneous magnetization of 4 magnetic yokes to achieve the effect of composite magnetization; controlling a group of magnetic poles at 90° to each other in the plane of 4 magnetic yokes to magnetize, and replacing them after one magnetization to achieve the effect of magnetic yoke method; (2) The robot has strong continuous operation capability. Compared with manual inspection, the inspection efficiency has been improved to a certain extent, and the inspection results are objective and are not affected by the fatigue level of the operator. (3) The automated magnetic particle inspection robot meets the requirements of different scenarios, industries and standards, and can easily realize the functions of composite magnetization and magnetic yoke. Attached Figure Description

[0009] The accompanying drawings described herein are merely illustrative of selected embodiments, not all possible implementations, and are not intended to limit the scope of the invention.

[0010] Figure 1 This is a perspective view of the overall structure of an embodiment of this application.

[0011] Figure 2 This is a side view of the overall structure of an embodiment of this application.

[0012] Figure 3 This is a front view of the overall structure of an embodiment of this application.

[0013] Figure 4 yes Figure 3 Enlarged view of point A in the middle.

[0014] Figure 5 This is a schematic diagram of the sliding frame structure in the embodiments of this application. Figure 1 .

[0015] Figure 6 This is a schematic diagram of the sliding frame structure in the embodiments of this application. Figure 2 .

[0016] Figure 7 This is a schematic diagram of the structure of the fixing component, clamping wheel, and detection module in the embodiments of this application.

[0017] Reference numerals: 1-Chassis, 11-Driving wheel, 12-Meter wheel, 13-Metal sensor, 14-Driven wheel, 2-Side rail, 21-Slider, 22-Support wheel, 23-Mounting block, 24-Screw, 3-Sliding frame, 31-Fixing plate, 32-Clamping block, 321-Slide groove, 33-Pressure rod, 34-Vertical rail, 4-Clamping wheel, 5-Detection module, 51-Nozzle, 52-Magnetic yoke, 53-Camera module, 54-Protective shell, 55-Cast, 6-Fixing component, 61-Fixing block, 7-Electrical box. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the implementation methods of the present invention will be described in detail below with reference to the accompanying drawings. However, the embodiments described in this invention are only some embodiments of the present invention, and not all embodiments.

[0019] This application provides an automated magnetic particle inspection robot for fillet welds, such as... Figures 1-7 As shown, it includes a vertically arranged chassis 1, a side slide rail 2, a sliding frame 3, a clamping wheel 4, and a detection module 5. The detection module 5 includes a nozzle 51 and a magnetic yoke 52. The nozzle 51 is used to spray magnetic suspension liquid, and the magnetic yoke 52 is used to provide the magnetic field required for detection.

[0020] like Figures 1-4 As shown, the chassis 1 is equipped with a drive wheel 11, a driven wheel 14, a measuring wheel 12, and a metal sensor 13. Specifically, the chassis 1 is a rectangular frame structure formed by the combination of an upper plate, a lower plate, a left plate, and a right plate. A middle plate is horizontally connected to the middle section inside the chassis 1. The drive wheel 11 is rotatably connected to the bottom of the middle plate and is driven by a motor. A pair of driven wheels 14 are provided, both of which are rotatably connected to the top of the lower rod. The measuring wheel 12 is located on the right side of the chassis 1 via a first bracket connected to the right plate. A pair of metal sensors 13 are provided and located on the left and right sides of the chassis 1, respectively, for detecting whether the chassis 1 has reached the end of the workpiece. The drive wheel 11, driven wheel 14, and measuring wheel 12 are all arranged to rotate around their own axes, and the axes are all arranged in the vertical direction. The front sides of the drive wheel 11, driven wheel 14, and measuring wheel 12 are flush, thus ensuring that the drive wheel 11, driven wheel 14, and measuring wheel 12 can all fit against the side of the wing plate during operation. The driven wheel 14 is used to assist walking and improve the movement stability of the detection robot, while the measuring wheel 12 is used to provide real-time feedback on the walking distance.

[0021] like Figures 1-6As shown, the side slide rail 2 is vertically connected to the front side of the chassis 1. A support wheel 22 is mounted below the side slide rail 2 via a second bracket. The support wheel 22 is used for rolling contact with the top surface of the wing plate, and its axis is aligned with the length direction of the side slide rail 2. Mounting blocks 23 are provided on the top surfaces of both the front and rear sides of the side slide rail 2. A screw 24 parallel to the length direction of the side slide rail 2 is rotatably connected between the two mounting blocks 23. A slider 21 is threaded through the screw 24, and one end of the screw 24 passes through the corresponding mounting block 23 and is connected to a first rotating head. Specifically, a guide rod parallel to the screw 24 is also connected between the two mounting blocks 23. The slider 21 slides along the guide rod to improve the stability of the slider 21 during movement.

[0022] like Figures 1-5 As shown, the sliding frame 3 is connected to the slider 21 and is mounted on the side slide rail 2 along the length of the side slide rail 2. An electrical box 7 and a water pump are provided above the sliding frame 3. The electrical box 7 is used to install the electrical components required by the detection robot, such as the power supply and control system. The left and right sides of the sliding frame 3 extend downwards symmetrically to form fixed plates 31. The two fixed plates 31 are provided with clamping blocks 32 on opposite sides. The clamping blocks 32 are vertically penetrated by a sliding groove 321. A vertical slide rail 34 is slidably fitted in the sliding groove 321. A pressure rod 33 is threaded through the clamping block 32 perpendicular to the vertical slide rail 34. The inner end of the pressure rod 33 is used to act on the vertical slide rail 34 to fix the vertical slide rail 34. The outer end of the pressure rod 33 is provided with a second rotating head. A fixing member 6 is connected between the bottoms of the two vertical slide rails 34.

[0023] like Figures 1-7As shown, the fixing member 6 includes a pair of fixing blocks 61, and a pair of clamping wheels 4 are respectively installed on the rear side of the two fixing blocks 61 via a third bracket. The clamping wheels 4 are rotatable around their own axis, and the axis is arranged in a vertical direction. The clamping wheels 4 are used to clamp the two sides of the wing plate with the driving wheel 11 respectively. The nozzle 51 is fixed below one of the fixing blocks 61 via a fourth bracket, and the nozzle 51 is connected to the water pump. Preferably, the nozzle 51 is inclined, and the inclination angle is preferably 45°. By utilizing gravity and impact force, it is ensured that the magnetic suspension can be fully flushed and To cover the dead corner at the root of the fillet weld and ensure clear defect display, a camera module 53 is located between two fixed blocks 61. The camera module 53 is used to acquire weld images and includes a camera, a white light, a UV light, and a circuit board. The white and UV lights provide sufficient illumination for the camera, which acquires fillet weld images for subsequent analysis. A pair of magnetic yokes 52 are located between the camera module 53 and the corresponding fixed blocks 61. Each magnetic yoke 52 includes two magnetic poles arranged at 90° to each other. By control, all four yokes can be magnetized simultaneously to achieve a composite magnetization effect. Alternatively, the two 90° poles in one yoke 52 can be magnetized individually and then replaced. The two yokes 52 work alternately to achieve the magnetic yoke effect. Specifically, a protective shell 54 is fitted over the magnetic yoke 52, and casters 55 are located below the protective shell 54 for auxiliary movement.

[0024] More specifically, handles are connected to both the left and right sides of the sliding frame 3 to facilitate the transfer of the inspection robot by the operator.

[0025] The work of the inspection robot includes the following steps.

[0026] Assembly and clamping: The operator places the inspection robot across the wing plate to be tested, with the drive wheel 11 and clamping wheel 4 positioned on the sides of the wing plate and the support wheel 22 positioned above the wing plate. The operator rotates the first rotating head, and the sliding frame 3 moves along the length of the side slide rail 2 to adjust the distance between the drive wheel 11 and the clamping wheel 4, so that the drive wheel 11 and the clamping wheel 4 are firmly attached to the wing plate, and the inspection robot and the wing plate are stably connected.

[0027] Alignment: Let the vertical slide rail 34 slide in the slide groove 321 to adjust the height of the fixing part 6. The specific height is adjusted according to the actual situation. It is necessary to ensure that the nozzle 51 can accurately spray the magnetic suspension liquid towards the fillet weld, and the fillet weld is located in the magnetic field generated by the magnetic yoke part 52. After the height is adjusted, rotate the second rotating head and use the pressure rod 33 to fix the vertical slide rail 34.

[0028] Automatic Inspection: Upon activation of the control system, the drive wheel 11 rotates via a motor, propelling the inspection robot forward at a constant speed along the workpiece's length. During this movement, three main actions—spraying, magnetization, and image acquisition—are automatically and synchronously completed. Specifically, nozzle 51 first sprays magnetic suspension liquid onto the fillet weld. The magnetic yoke 52 generates an alternating magnetic field at the fillet weld. If discontinuous defects such as cracks exist on or near the surface of the fillet weld, the magnetic lines of force will undergo local distortion, forming a leakage magnetic field. This attracts ferromagnetic powder from the magnetic suspension liquid, creating magnified, visible magnetic traces. Finally, a camera acquires images of these magnetic traces under suitable lighting conditions, and the meter wheel 12 records the precise mileage of the defect in real time. The alternating magnetic field is achieved by supplying alternating current or commutated direct current to the magnetic yoke 52, causing the direction or magnitude of the magnetic field at the fillet weld to change periodically. This magnetic field can cut cracks in any direction, allowing for the detection of transverse, longitudinal, and oblique defects without changing the orientation of the inspection module 5 during the inspection process. A single inspection is sufficient for more comprehensive detection, improving efficiency and preventing missed detections.

[0029] Shutdown: When the metal sensor 13 extends beyond the end of the workpiece, that is, when the inspection robot moves to the end of the workpiece, the metal sensor 13 will not detect metal and will send an electrical signal to the control system to cut off the power. Finally, the operator will remove the inspection robot from the wing plate.

[0030] In application, the above description is only a preferred embodiment of this application and is not intended to limit this application. Obviously, those skilled in the art can make various modifications and variations to this application without departing from the spirit and scope of this application.

Claims

1. An automated magnetic particle inspection robot for fillet welds, characterized in that, The chassis (1) is set vertically, on which a drive wheel (11) is provided. A side slide rail (2) is connected to the front of the chassis (1). A sliding frame (3) is moved on the side slide rail (2). A fixing member (6) is connected to the sliding frame (3). A clamping wheel (4) and a detection module (5) are fixed on the fixing member (6). The drive wheel (11) and the clamping wheel (4) both rotate around their own axis and are set vertically. The drive wheel (11) and the clamping wheel (4) are used to clamp the wing plate. The detection module (5) has a nozzle (51) and a magnetic yoke (52). The nozzle (51) is used to spray magnetic suspension liquid, and the magnetic yoke (52) is used to provide the magnetic field required for detection.

2. The automated magnetic particle inspection robot for fillet welds according to claim 1, characterized in that, A pair of support wheels (22) are provided below the side slide rail (2). The support wheels (22) roll in contact with the top surface of the wing plate, and their axis direction is parallel to the length direction of the side slide rail (2).

3. The automated magnetic particle inspection robot for fillet welds according to claim 1, characterized in that, The side slide rail (2) has mounting blocks (23) on its front and rear top surfaces respectively. A screw (24) is rotatably mounted between the two mounting blocks (23). A slider (21) is connected to the screw (24) by a thread. The slider (21) is connected to the sliding frame (3).

4. The automated magnetic particle inspection robot for fillet welds according to claim 1, characterized in that, The sliding frame (3) has fixed plates (31) that are symmetrical and extend downward on the left and right sides respectively. The fixed plates (31) are provided with clamping blocks (32). The clamping blocks (32) are provided with sliding grooves (321) along the vertical direction. The vertical slide rail (34) is slidably provided in the sliding grooves (321). One side of the clamping blocks (32) is connected to a pressure rod (33) by a thread. The inner end of the pressure rod (33) abuts against the outer wall of the vertical slide rail (34). The fixing member (6) is fixed to the lower end of the vertical slide rail (34).

5. The automated magnetic particle inspection robot for fillet welds according to claim 1, characterized in that, A measuring wheel (12) is mounted on the chassis (1) via a rotating shaft. The axis of the measuring wheel (12) is parallel to the axis of the drive wheel (11), and the front side of the measuring wheel (12) is flush with the front side of the drive wheel (11).

6. The automated magnetic particle inspection robot for fillet welds according to claim 1, characterized in that, A metal sensor (13) is provided on one side of the chassis (1).

7. The automated magnetic particle inspection robot for fillet welds according to claim 1, characterized in that, The fastener (6) includes a pair of fastening blocks (61), a pair of clamping wheels (4) which are respectively installed on the rear side of the two fastening blocks (61), a nozzle (51) is fixed below one of the fastening blocks (61), a camera module (53) is provided between the two fastening blocks (61), the camera module (53) is used to collect weld images, a pair of magnetic yokes (52) are respectively located between the camera module (53) and the fastening block (61) on the side where they are located, a protective shell (54) is provided on the outside of the magnetic yoke (52), and a caster (55) is provided below the protective shell (54).

8. The automated magnetic particle inspection robot for fillet welds according to claim 1, characterized in that, A driven wheel (14) is provided on the chassis (1) via a rotating shaft. Its axis is parallel to the axis of the driving wheel (11), and the front side of the driven wheel (14) is flush with the front side of the driving wheel (11).

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